Method of manufacturing mirror assembly with spring-loaded electrical connectors

ABSTRACT

A method of manufacturing a rearview mirror assembly for a vehicle includes providing an electro-optic reflective element and a back plate. First and second spring-loaded electrical connectors are disposed in respective passageways of the back plate. A circuit element is provided that has an electrically conductive trace electrically connected to control circuitry. The back plate is attached at the reflective element, and the circuit element is attached at the back plate. With the back plate attached at the reflective element and with the circuit element attached at the back plate, the spring-loaded electrical connectors are biased into electrical contact with a respective electrically conductive element at the reflective element and a respective electrically conductive trace at the circuit element to electrically connect the electrically conductive trace to the electrically conductive element.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 15/051,824, filed Feb. 24, 2016, now U.S. Pat. No. 9,878,669, which claims the filing benefits of U.S. provisional applications, Ser. No. 62/198,881, filed Jul. 30, 2015, Ser. No. 62/169,705, filed Jun. 2, 2015, and Ser. No. 62/120,039, filed Feb. 24, 2015, which are hereby incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to the field of interior rearview mirror assemblies for vehicles and, more particularly, to interior rearview mirror assemblies having a variable reflectance reflective element and circuitry for electrically connecting to the electrically conductive coatings of the variable reflectance reflective element.

BACKGROUND OF THE INVENTION

It is known to provide a mirror assembly that is adjustably mounted to an interior portion of a vehicle, such as via a double ball pivot or joint mounting configuration where the mirror casing and reflective element are adjusted relative to the interior portion of a vehicle by pivotal movement about the double ball pivot configuration. The reflective element may be an electrochromic reflective element having an electrochromic medium sandwiched between front and rear substrates coated with electrically conductive coatings, whereby, when powered, the transmissivity of the reflective element is varied. Typically, electrical connection to the conductive coatings is provided via soldering to clips that clip onto an edge portion of the respective substrate.

SUMMARY OF THE INVENTION

The present invention provides a rearview mirror assembly that provides spring-loaded electrical connectors that electrically connect between circuitry on a circuit element (such as a printed circuit board or the like) and electrically conductive elements established at the rear of the reflective element (such as at the fourth or rear surface of an electro-optic mirror reflective element). The electrically conductive elements may comprise electrically conductive traces that are electrically conductively connected to electrically powered elements at the reflective element, such as the electrically conductive coatings at the second and third surfaces of an electro-optic mirror reflective element. The spring-loaded electrical connectors are urged or biased into electrical contact with the electrically conductive traces and electrically conductive elements as the back plate is attached at the rear of the reflective element and/or as the circuit board or element is attached at the back plate.

These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an interior rearview mirror assembly in accordance with the present invention;

FIG. 2 is a sectional view of the mirror reflective element assembly of the mirror assembly of FIG. 1;

FIG. 3 is an exploded perspective view of the mirror reflective element assembly of the present invention;

FIG. 4 is an enlarged sectional view of the mirror reflective element assembly of FIG. 3;

FIG. 5 is an exploded perspective view of another interior rearview mirror assembly, with a spring connector in accordance with the present invention;

FIG. 6 is an enlarged view of the spring connector of FIG. 5;

FIG. 7 is a perspective view of the spring connector, showing its connection to a metallic connector pad at the rear surface of the mirror reflective element;

FIG. 8 is a side elevation of the connection of FIG. 7;

FIG. 9 is a perspective view of a connector pad configured to clip onto a conventional electrode clip attached along an edge of a substrate of a mirror reflective element in accordance with the present invention; and

FIG. 10 is a side view and partial sectional view of the connector pad and conventional electrode clip of FIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depicted therein, an interior rearview mirror assembly 10 for a vehicle includes a casing 12 and a reflective element 14 positioned at a front portion of the casing 12 (FIG. 1). In the illustrated embodiment, mirror assembly 10 is configured to be adjustably mounted to an interior portion of a vehicle (such as to an interior or in-cabin surface of a vehicle windshield or a headliner of a vehicle or the like) via a mounting structure or mounting configuration or assembly 16. The mirror reflective element comprises a variable reflectance mirror reflective element that varies its reflectance responsive to electrical current applied to conductive coatings or layers of the reflective element. The reflective element 14 is attached at a back plate 30 and, when a circuit element or circuit board 32 is attached at the back plate, spring-loaded or spring-biased connectors 34 make electrical connection between circuitry on the circuit element 32 and respective electrically conductive coatings or elements at the rear of the mirror reflective element 14, as discussed below.

In the illustrated embodiment, and as shown in FIG. 2, the mirror reflective element 14 comprises a laminate construction variable reflectance electro-optic (such as electrochromic) reflective element assembly having a front substrate 18 and a rear substrate 20 with an electro-optic medium 22 (such as electrochromic medium) sandwiched therebetween and bounded by a perimeter seal 24. As shown in FIG. 2, front substrate 18 has a front or first surface 18 a (the surface that generally faces the driver of a vehicle when the mirror assembly is normally mounted at the vehicle) and a rear or second surface 18 b opposite the front surface 18 a, and rear substrate 20 has a front or third surface 20 a and a rear or fourth surface 20 b opposite the front surface 20 a, with the electro-optic medium 22 disposed between the second surface 18 b and the third surface 20 a and bounded by the perimeter seal 24 of the reflective element (such as is known in the electrochromic mirror art). The second surface 18 a has a transparent conductive coating 26 established thereat (such as an indium tin oxide (ITO) layer, or a doped tin oxide layer or any other transparent electrically semi-conductive layer or coating or the like (such as indium cerium oxide (ICO), indium tungsten oxide (IWO), or indium oxide (IO) layers or the like or a zinc oxide layer or coating, or a zinc oxide coating or the like doped with aluminum or other metallic materials, such as silver or gold or the like, or other oxides doped with a suitable metallic material or the like, or such as disclosed in U.S. Pat. No. 7,274,501, which is hereby incorporated herein by reference in its entirety), while the third surface 20 a has a metallic reflector coating 28 (or multiple layers or coatings) established thereat. The front or third surface 20 a of rear substrate 20 may include one or more transparent semi-conductive layers (such as an ITO layer or the like), and one or more metallic electrically conductive layers (such as a layer of silver, aluminum, chromium or the like or an alloy thereof), and may include multiple layers such as disclosed in U.S. Pat. Nos. 7,274,501; 7,184,190 and/or 7,255,451, which are hereby incorporated herein by reference in their entireties. The mirror reflector may comprise any suitable coatings or layers, such as a transflective coating or layer, such as described in U.S. Pat. Nos. 7,626,749; 7,274,501; 7,255,451; 7,195,381; 7,184,190; 6,690,268; 5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,511; 5,567,360; 5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012; 5,115,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or 4,712,879, which are hereby incorporated herein by reference in their entireties, disposed at the front surface of the rear substrate (commonly referred to as the third surface of the reflective element) and opposing the electro-optic medium, such as an electrochromic medium disposed between the front and rear substrates and bounded by the perimeter seal (but optionally, the mirror reflector could be disposed at the rear surface of the rear substrate (commonly referred to as the fourth surface of the reflective element), while remaining within the spirit and scope of the present invention).

The third surface 20 a defines the active EC area or surface of the rear substrate within the perimeter seal 24. The coated third surface 20 a may also be coated to define a tab-out region and wrap around coating or portion 28 a (such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 7,274,501; 7,184,190 and/or 7,255,451, which are hereby incorporated herein by reference in their entireties) that wraps around the perimeter edge of the rear substrate and overcoats a portion of the rear or fourth surface 20 b of the rear substrate. The wrap around portion 28 a thus provides electrical connection of the conductive layers 28 to an electrically conductive pad or bus-bar or element 28 b established or disposed at the rear surface of the rear substrate for electrical connection to a spring-loaded connector 34. Optionally, the conductive pad 28 b may comprise a conductive metal pad or element or tab that is adhered or otherwise established at the fourth surface and that is electrically conductively connected to the third surface coating 28 via a conductive epoxy or the like.

Likewise, an electrically conductive pad or bus-bar or element 29 a (which may be a coating established at the rear surface of the rear substrate or may be a metal pad or electrically conductive element adhered or otherwise attached or bonded or established or disposed at the rear surface of the rear substrate) may be established at another region of the rear surface of the rear substrate for electrical connection to another spring-loaded connector 34. The conductive pad 29 a may be electrically connected to the electrically conductive transparent coating 26 at the rear or second surface 18 b of the front substrate 18, such as via a conductive epoxy 29 b or the like established along a portion of a perimeter region of the reflective element (and at a region where the perimeter seal 24 may electrically isolate the coating 28 at the rear surface of the rear substrate from the conductive epoxy 29 b, such as can be seen in FIG. 2).

As can be seen with reference to FIGS. 3 and 4, the back plate 30 receives the reflective element 14 therein, with the electrically conductive pads 28 b, 29 a exposed at the rear surface of the reflective element. The back plate 30 includes apertures or passageways 30 a therethrough that receive the connectors 34 (such as shown in FIG. 4). The back plate 30 (such as a generally planar portion 30 c of the back plate 30) is attached at the rear surface of the reflective element, such as via an adhesive layer or element or tape 38 disposed between and attaching an attachment surface of the back plate 30 at the rear surface of the reflective element. The pads 28 b, 29 a are disposed at locations at the rear of the reflective element 14 where, when the back plate 30 is attached at the reflective element via the adhesive layer or element 38, the adhesive element 38 has corresponding openings or apertures and where the respective passageways 30 a are located, such that the electrical connectors 34 electrically connect with the pads or elements 28 b, 29 a at the passageways 30 a.

When the electrical connectors are received in the passageways 30 a, the connectors 34 float or are movable along the passageway, with the movement limited by a flange or lip 30 b of the back plate 30 and spaced apart flanges or lips 34 a, 34 b of the connector 34. The connectors 34 thus may be pressed into the passageways 30 a (such as in an upward direction as shown in FIG. 4), whereby, after insertion, the connectors may move along the passageways but will not fall out of the passageways.

The connectors 34 have a length dimension (when not compressed) that is larger than the thickness of the back plate at the passageways, such that the contacts or ends 34 c, 34 d of the connectors may protrude from either side or both sides of the back plate. The metallic or electrically conductive contact end 34 c is movable relative to the connector body and contact end 34 d to compress or expand the connector, and is biased towards its extended state via an internal spring 34 e. As shown in FIG. 4, the contact end 34 d contacts the respective conductive pad or element 28 b, 29 a at the rear of the reflective element when the back plate is attached at the reflective element.

The circuit element 32 (such as a printed circuit board or PCB) is configured to snap attach at the back plate (such as via one or more clasps or tabs 30 d that engage the circuit board substrate 32 a, as shown in FIG. 4). When the circuit element 32 is attached at the back plate 30, respective circuitry (such as conductive traces of the PCB that are electrically connected to control circuitry, such as EC control circuitry, of the PCB) of the circuit element engages or electrically contacts the contact end 34 c of the respective connector 34, whereby the connector compresses as it is sandwiched between the circuit board and the reflective element to establish electrical connection between both ends of the connector and the circuitry at the circuit element and the conductive pads at the rear of the reflective element, with the compressed spring biasing the contact ends towards the circuit element and the rear surface of the reflective element to maintain the electrical connection.

Thus, the spring-loaded electrical connector of the present invention may be formed of a first, generally tubular, metallic stamping or form or body portion having a first cross-sectional dimension, and a second, generally tubular, metallic stamping or form or body portion having a second cross-sectional dimension. The shape, form and cross-sectional dimension of the second body portion is smaller than that of the first body portion, such that the second body portion is disposed within the first body portion and is slidable along and within the first body portion. A spring or other biasing element is disposed within at least the first body portion and enables the second body portion to move within and along the inner walls of the first body portion. The spring element urges the second body portion outward from the first body portion to extend the connector to its extended state (where the length of the connector is greater than the thickness of the back plate in and through which it is disposed), with the spring element compressing to allow the connector to compress as the back plate is attached at the rear surface of the reflective element and as the circuit board or element is attached at the back plate.

The electrical connector and/or the back plate include retention tabs or flanges or elements to limit removal of the electrical connector from the back plate such that the back plate (with the electrical connectors disposed therein) can be moved and handled when it is not attached at the reflective element and/or circuit board, with the electrical connector remaining at the respective passageway of the back plate. The back plate (with the electrical connectors disposed therein) can be attached at the rear surface of the reflective element and then later the circuit board may be snap-attached at the back plate and reflective element construction to compress the electrical connectors and establish the electrical connection between the circuitry of the circuit board and the electrically conductive elements at the reflective element, or the circuit board can be attached to the back plate (with the electrical connectors disposed therein), whereby the back plate and circuit board can be later attached at the rear surface of the reflective element to compress the electrical connectors and establish the electrical connection between the circuitry of the circuit board and the electrically conductive elements at the reflective element. The spring-loaded electrical connector of the present invention thus provides enhanced assembly and electrical connection of mirror reflective element sub-assemblies.

Thus, the present invention provides spring-loaded electrical connectors that establish electrical connection between circuitry on a PCB and electrical contacts at the rear of the reflective element during assembly of the PCB to the back plate. The present invention thus reduces or eliminates wiring connectors and soldering of connectors at the reflective element. The spring force of the internal spring of the connector may be selected to be sufficient to establish and maintain electrical connection during and after assembly. For example, the spring force may be at least about 1 N, preferably at least about 1.5 N or thereabouts. The connector contact ends and body comprise a metallic or otherwise electrically conductive material and the spring also comprises a metallic or otherwise electrically conductive material such that electrical current can pass from one contact end to the other when one of the ends is electrically powered (and when the other end is electrically connected to circuitry to power).

In the illustrated embodiment, two electrical connectors are provided to establish electrical connection between EC control circuitry of the PCB to the electrically conductive coatings at the second and third surfaces of the reflective element. However, spring-loaded electrical connectors may also or otherwise provide electrical connection between circuitry of the PCB and contacts for other electrically powered or controlled elements, such as sensors or heater pads (for exterior mirror applications) or the like, while remaining within the spirit and scope of the present invention.

For example, one or more spring-loaded electrical connectors may be disposed in the back plate of an exterior rearview mirror assembly and configured to electrically connect with conductive pads or elements of a heater pad disposed at the rear of the mirror reflective element (and between a generally planar portion of the back plate and the mirror reflective element). The heater pad spring-loaded electrical connectors electrically connect to circuitry at the circuit board (such as when the circuit board is attached or snap-attached at the back plate) and provide power and/or control to the heater pad to control heating of the mirror reflective element of the exterior rearview mirror assembly. Optionally, other spring-loaded electrical connectors may be provided at and through the back plate for electrically connecting circuitry of the circuit board to other electrically powered elements or devices, such as one or more light sources or indicators disposed at the rear of the mirror reflective element (and viewable through the reflective element when powered). Thus, multiple spring-loaded electrical connectors of the present invention may be provided at and through the back plate to provide the desired electrical power and control of one or more electrically powered devices or element.

The present invention thus provides spring-loaded electrical connectors that electrically connect between the PCB and conductive coatings or pads at the rear of an electro-optic reflective element, with the connectors being snapped into the attachment plate or back plate with the ends protruding from one or both sides of the back plate. The pins or connectors are thus part of the back plate and are positioned at the rear of the reflective element when the reflective element is attached at or received in the back plate. Thus, when the reflective element is attached or received at the back plate, that end of the pin or connector may engage or may be pressed into engagement with the pads at the fourth surface and, when the PCB is snapped onto the back plate, the other end of the connector is pressed into engagement with circuitry of the PCB, thus connecting the PCB circuitry to the respective EC cell conductive coatings. The present invention thus provides enhanced assembly of the mirror reflective element assembly, particularly for frameless type mirror reflective elements that may not have an overlap or offset region of the substrates for a clip attachment. The conductive pads are established at the rear of the rear substrate and the spring-loaded or biased pins or connectors are disposed in the back plate and make connection between the conductive pads and circuitry or traces at the PCB when the PCB is attached at the back plate. The pins are then held in place by the attachment of the PCB and maintain the electrical connection of the circuitry to the conductive coatings of the reflective element. Such a configuration eases the assembly of the mirror and facilitates automated assembly and connections.

Optionally, the spring-loaded electrical connectors may be insert molded in the back plate (such as during an injection molding process that forms the plastic back plate), with the ends of the connector protruding at either side of the back plate. Optionally, the spring-loaded connector may be provided disposed in a plastic (non-electrically conductive) sleeve and may be longitudinally movable along a passageway of the sleeve (so as to generally float in the passageway of the sleeve), with one or more flanges of the connector and the sleeve interacting to limit longitudinal movement of the connector within and relative to the sleeve. The sleeves (with the respective spring-loaded connectors disposed therein) may be disposed in the mold for the back plate such that, when the back plate is molded (via an injection molding process), the sleeves are integral to the back plate and held in place by the molded back plate that is molded around the sleeves (which may have one or more exterior protrusions that are molded over by the back plate to further secure the sleeves relative to the molded back plate).

Optionally, the connectors may comprise a flexible spring metallic clip or connector (that is biased or spring-biased towards its initial shape or form) that flexes as the circuit board is moved towards the rear of the reflective element and as the connector engages a connector pad or element at the rear surface of the reflective element. For example, and with reference to FIGS. 5-8, a flexible spring clip or spring-biased connector 134 may be attached at the circuit board 132 (and electrically connected to circuitry of the circuit board) and may extend therefrom a selected distance such that, when the circuit board 132 is attached at the back plate 130 at the rear of the reflective element 114, the connector 134 engages an electrically conductive pad or element at the rear surface of the reflective element to electrically connect the circuitry of the circuit board to the electrically conductive coating or coatings of the reflective element. The connector 134 comprises a flexible metallic electrically conductive material and is sized so as to be larger than the gap between the circuit board and the conductive element at the rear surface of the reflective element when the circuit board is attached at the back plate of the mirror reflective element.

Thus, when the circuit board (with the connector attached thereto or integrally formed thereat) is pressed into a snap attachment with the back plate, the electrical connector 134 engages the conductive element at the rear surface of the reflective element and flexes. Because the connector preferably comprises a spring element, it is biased towards its initial state and thus exerts a contact force or pressure at the conductive element at the rear surface of the reflective element to maintain appropriate electrical contact between the circuitry of the circuit board and the conductive element at the rear surface of the reflective element.

The flexible spring clip connector 134 thus provides solderless electrical connection between circuitry of the circuit board and the conductive element at the rear surface of the reflective element. Optionally, the connector may be insert formed or clipped or connected at least partially in the circuit board substrate such that the connector is part of the circuit board and is received through an aperture in the back plate when the circuit board (with the connector attached thereto or integrally formed thereat) is pressed into a snap attachment with the back plate. Optionally, the connector may be insert molded in the back plate (such as during an injection molding process that forms the plastic back plate), with flexible or spring-biased portions of the connector protruding at either side of the back plate, whereby both portions flex as they engage with the circuit board and the conductive element at the rear surface of the reflective element, respectively, and are biased toward electrical contact with the circuit board and conductive element.

The present invention thus provides flexible or spring-biased or spring-loaded electrical connectors that electrically connect between the PCB and conductive coatings or pads at the rear of an electro-optic reflective element. The connectors may be part of the circuit board or part of the back plate and are positioned at the rear of the reflective element when the reflective element is attached at or received in the back plate. Thus, when the reflective element is attached or received at the back plate, that end of the connector may engage or may be pressed into engagement with the pads at the fourth surface and, when the PCB is snapped onto the back plate, the other end of the connector is pressed into engagement with circuitry of the PCB, thus connecting the PCB circuitry to the respective EC cell conductive coatings. The present invention thus provides enhanced assembly of the mirror reflective element assembly, particularly for frameless type mirror reflective elements that may not have an overlap or offset region of the substrates for a clip attachment. The connectors are held in place by the attachment of the PCB and maintain the electrical connection of the circuitry to the conductive coatings of the reflective element. Such a configuration eases the assembly of the mirror and facilitates automated assembly and connections.

Optionally, the electrical connection of the present invention may be made to conventional electrode clips attached at a perimeter edge region of a glass substrate of the mirror reflective element (whereby the electrode clip makes electrical contact with a conductive coating on one of the surfaces of the substrate, such as with a conductive coating at the front or third surface of the rear substrate or with a transparent conductive coating at the rear or second surface of the front substrate). For example, and such as shown in FIGS. 9 and 10, a connector pad 234 has a pad portion 234 a that may attach at the back plate and includes an extension or clip portion 234 b configured to extend over and snap to an electrode clip 236 already attached at the perimeter edge of the rear substrate) when the back plate (and connector pad) is attached at the rear surface of the rear substrate of the mirror reflective element. In a similar manner, another connector pad may have an extension or clip portion that extends further from the pad portion to snap attach and electrically connect to an electrode clip at a perimeter edge of the front substrate. For example, a connector pad for the rear substrate electrode clip may have its clip portion along one perimeter region of the rear substrate (such as along an upper or lower region) and the other connector pad (for the front substrate electrode clip) may have its clip portion along an opposite perimeter region (such as along the lower or upper region). The extension or clip portions of the connector pads of the present invention thus may snap attach at the respective electrode clip as the back plate is attached, thus easing the assembly process and electrical connection of electro-optic control circuitry to the conductive coatings at the surfaces of the mirror reflective element substrates that oppose and contact the electro-optic medium. The spring-loaded or spring-biased electrical connectors of the present invention may then electrically connect to the connector pads when the back plate is attached at the reflective element and/or when the circuit board is attached at the back plate, such as in a similar manner as discussed above.

The mirror casing may include a bezel portion that circumscribes a perimeter region of the front surface of the reflective element, or the perimeter region of the front surface of the reflective element may be exposed (such as by utilizing aspects of the mirror reflective elements described in International Publication Nos. WO 2010/124064; WO 2011/044312; WO 2012/051500; WO 2013/071070 and/or WO 2013/126719, which are hereby incorporated herein by reference in their entireties).

The back plate may comprise any suitable construction. Optionally, for example, a common or universal back plate, whereby the appropriate or selected socket element or pivot element (such as a socket element or such as a ball element or the like) is attached to the back plate to provide the desired pivot joint for the particular mirror head in which the back plate is incorporated. Optionally, when molding the back plate, a different insert may be provided to integrally mold a portion of or all of a ball member or the like (such as a portion of a base of a ball member, whereby the ball member may comprise a metallic ball member that is insert molded at the base and at the rear of the back plate during the injection molding process that forms the back plate, such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 7,855,755; 7,249,860 and 6,329,925 and/or U.S. Pat. Pub. Nos. US-2013-0088884 and/or US-2006-0061008, which are hereby incorporated herein by reference in their entireties).

The reflective element and mirror casing are adjustable relative to a base portion or mounting assembly to adjust the driver's rearward field of view when the mirror assembly is normally mounted at or in the vehicle. The mounting assembly may comprise a single-ball or single-pivot mounting assembly, whereby the reflective element and casing are adjustable relative to the vehicle windshield (or other interior portion of the vehicle) about a single pivot joint, or the mounting assembly may comprise other types of mounting configurations, such as a double-ball or double-pivot mounting configuration or the like, while remaining within the spirit and scope of the present invention. The socket or pivot element is configured to receive a ball member of the base portion, such as for a single pivot or single ball mounting structure or a double pivot or double ball mounting structure or the like (such as a pivot mounting assembly of the types described in U.S. Pat. Nos. 6,318,870; 6,593,565; 6,690,268; 6,540,193; 4,936,533; 5,820,097; 5,100,095; 7,249,860; 6,877,709; 6,329,925; 7,289,037; 7,249,860 and/or 6,483,438, which are hereby incorporated herein by reference in their entireties).

The mounting base includes an attaching portion that is configured to be attached to an interior surface of a vehicle windshield (such as to a mounting button or attachment element adhered to the interior surface of the vehicle windshield or such as to a headliner or overhead console of the vehicle). The mounting base may comprise a metallic ball portion or may comprise a molded (such as injection molded) polymeric mounting base or may be otherwise formed, depending on the particular application of the mirror assembly.

The mirror assembly may comprise any suitable construction, such as, for example, a mirror assembly with the reflective element being nested in the mirror casing and with a bezel portion that circumscribes a perimeter region of the front surface of the reflective element, or with the mirror casing having a curved or beveled perimeter edge around the reflective element and with no overlap onto the front surface of the reflective element (such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 7,255,451; 7,289,037; 7,360,932; 8,049,640; 8,277,059 and/or 8,529,108, or such as a mirror assembly having a rear substrate of an electro-optic or electrochromic reflective element nested in the mirror casing, and with the front substrate having curved or beveled perimeter edges, or such as a mirror assembly having a prismatic reflective element that is disposed at an outer perimeter edge of the mirror casing and with the prismatic substrate having curved or beveled perimeter edges, such as described in U.S. Des. Pat. Nos. D633,423; D633,019; D638,761 and/or D647,017, and/or International Publication Nos. WO 2010/124064; WO 2011/044312; WO 2012/051500; WO 2013/071070 and/or WO 2013/126719, which are hereby incorporated herein by reference in their entireties (and with electrochromic and prismatic mirrors of such construction are commercially available from the assignee of this application under the trade name INFINITY™ mirror).

As discussed above, the mirror assembly may comprise an electro-optic or electrochromic mirror assembly that includes an electro-optic or electrochromic reflective element. The perimeter edges of the reflective element may be encased or encompassed by the perimeter element or portion of the bezel portion to conceal and contain and envelop the perimeter edges of the substrates and the perimeter seal disposed therebetween. The electrochromic mirror element of the electrochromic mirror assembly may utilize the principles disclosed in commonly assigned U.S. Pat. Nos. 7,274,501; 7,255,451; 7,195,381; 7,184,190; 6,690,268; 5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360; 5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012; 5,117,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and/or 4,712,879, which are hereby incorporated herein by reference in their entireties.

Although shown as an electrochromic mirror application, it is envisioned that the mirror assembly may comprise a prismatic reflective element, while remaining within the spirit and scope of the present invention. The prismatic mirror assembly may be mounted or attached at an interior portion of a vehicle (such as at an interior surface of a vehicle windshield) via the mounting means described above, and the reflective element may be toggled or flipped or adjusted between its daytime reflectivity position and its nighttime reflectivity position via any suitable toggle means, such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 6,318,870 and/or 7,249,860, and/or U.S. Publication No. US-2010-0085653, which are hereby incorporated herein by reference in their entireties. Optionally, for example, the interior rearview mirror assembly may comprise a prismatic mirror assembly, such as the types described in U.S. Pat. Nos. 7,289,037; 7,249,860; 6,318,870; 6,598,980; 5,327,288; 4,948,242; 4,826,289; 4,436,371 and/or 4,435,042, which are hereby incorporated herein by reference in their entireties. Optionally, the prismatic reflective element may comprise a conventional prismatic reflective element or prism or may comprise a prismatic reflective element of the types described in U.S. Pat. Nos. 7,420,756; 7,289,037; 7,274,501; 7,249,860; 7,338,177 and/or 7,255,451, which are all hereby incorporated herein by reference in their entireties, without affecting the scope of the present invention. A variety of mirror accessories and constructions are known in the art, such as those disclosed in U.S. Pat. Nos. 5,555,136; 5,582,383; 5,680,263; 5,984,482; 6,227,675; 6,229,319 and/or 6,315,421 (which are hereby incorporated herein by reference in their entireties), that can benefit from the present invention.

Optionally, the reflective element may include an opaque or substantially opaque or hiding perimeter layer or coating or band disposed around a perimeter edge region of the front substrate (such as at a perimeter region of the rear or second surface of the front substrate) to conceal or hide or the perimeter seal from viewing by the driver of the vehicle when the mirror assembly is normally mounted in the vehicle. Such a hiding layer or perimeter band may be reflective or not reflective and may utilize aspects of the perimeter bands and mirror assemblies described in U.S. Pat. Nos. 5,066,112; 7,626,749; 7,274,501; 7,184,190 and/or 7,255,451, and/or International Publication Nos. WO 2010/124064 and/or WO 2011/044312, which are all hereby incorporated herein by reference in their entireties. Optionally, the perimeter band may comprise a chrome/chromium coating or metallic coating and/or may comprise a chrome/chromium or metallic coating that has a reduced reflectance, such as by using an oxidized chrome coating or chromium oxide coating or “black chrome” coating or the like (such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 7,184,190 and/or 7,255,451, which are hereby incorporated herein by reference in their entireties). Optionally, other opaque or substantially opaque coatings or bands may be implemented while remaining within the spirit and scope of the present invention.

Optionally, the interior rearview mirror assembly may include circuitry therein (such as at a printed circuit board or the like disposed within the mirror casing, and electrical connection to the circuitry may be made via an electrical lead or connector of a wiring harness of the vehicle. Optionally, the electrical connector may be received through the mirror casing and through an aperture established through the toggle element, such as by utilizing aspects of the mirror assemblies described in U.S. Pat. No. 5,798,688 and/or U.S. Publication No. US-2010-0085653, which are hereby incorporated herein by reference in their entireties.

The mirror assembly may include user actuatable inputs operable to control any of the accessories of or associated with the mirror assembly and/or an accessory module or the like. For example, the mirror assembly may include touch sensitive elements or touch sensors or proximity sensors, such as the types of touch sensitive elements described in U.S. Pat. Nos. 5,594,222; 6,001,486; 6,310,611; 6,320,282; 6,627,918; 7,224,324 and/or 7,253,723, and/or International Publication Nos. WO 2012/051500 and/or WO 2013/071070, which are hereby incorporated herein by reference in their entireties, or such as proximity sensors of the types described in U.S. Pat. Nos. 7,224,324; 7,249,860 and/or 7,446,924, and/or International Publication No. WO 2004/058540, which are hereby incorporated herein by reference in their entireties, or such as membrane type switches, such as described in U.S. Pat. No. 7,360,932, which is hereby incorporated herein by reference in its entirety, or such as detectors and the like, such as the types disclosed in U.S. Pat. Nos. 7,255,541; 6,504,531; 6,501,465; 6,492,980; 6,452,479; 6,437,258 and/or 6,369,804, which are hereby incorporated herein by reference in their entireties, and/or the like, while remaining within the spirit and scope of the present invention.

Optionally, the user inputs or buttons may comprise user inputs for a garage door opening system, such as a vehicle based garage door opening system of the types described in U.S. Pat. Nos. 6,396,408; 6,362,771; 7,023,322 and/or 5,798,688, which are hereby incorporated herein by reference in their entireties. Optionally, the user inputs may also or otherwise comprise user inputs for a telematics system of the vehicle, such as, for example, an ONSTAR® system as found in General Motors vehicles and/or such as described in U.S. Pat. Nos. 4,862,594; 4,937,945; 5,131,154; 5,255,442; 5,632,092; 5,798,688; 5,971,552; 5,924,212; 6,243,003; 6,278,377; 6,420,975; 6,477,464; 6,946,978; 7,308,341; 7,167,796; 7,004,593; 7,657,052 and/or 6,678,614, and/or U.S. Pat. Pub. No. US-2006-0050018, which are all hereby incorporated herein by reference in their entireties.

Optionally, the mirror assembly may include one or more other displays, such as the types disclosed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925, which are hereby incorporated herein by reference in their entireties, and/or display-on-demand transflective type displays, and/or video displays or display screens, such as the types disclosed in U.S. Pat. Nos. 8,890,955; 7,855;755; 7,338,177; 7,274,501; 7,255,451; 7,195,381; 7,184,190; 7,046,448; 5,668,663; 5,724,187; 5,530,240; 6,329,925; 6,690,268; 7,734,392; 7,370,983; 6,902,284; 6,428,172; 6,420,975; 5,416,313; 5,285,060; 5,193,029 and/or 4,793,690, and/or in U.S. Pat. Pub. Nos. US-2006-0050018; US-2009-0015736; US-2009-0015736 and/or US-2010-0097469, which are all hereby incorporated herein by reference in their entireties.

Optionally, the mirror assembly may include one or more other accessories at or within the mirror casing, such as one or more electrical or electronic devices or accessories, such as antennas, including global positioning system (GPS) or cellular phone antennas, such as disclosed in U.S. Pat. No. 5,971,552, a communication module, such as disclosed in U.S. Pat. No. 5,798,688, a blind spot detection system, such as disclosed in U.S. Pat. Nos. 5,929,786 and/or 5,786,772, transmitters and/or receivers, such as a garage door opener or the like, a digital network, such as described in U.S. Pat. No. 5,798,575, a high/low headlamp controller, such as disclosed in U.S. Pat. Nos. 5,796,094 and/or 5,715,093, a memory mirror system, such as disclosed in U.S. Pat. No. 5,796,176, a hands-free phone attachment, a video device for internal cabin surveillance and/or video telephone function, such as disclosed in U.S. Pat. Nos. 5,760,962 and/or 5,877,897, a remote keyless entry receiver, lights, such as map reading lights or one or more other lights or illumination sources, such as disclosed in U.S. Pat. Nos. 6,690,268; 5,938,321; 5,813,745; 5,820,245; 5,673,994; 5,649,756; 5,178,448; 5,671,996; 4,646,210; 4,733,336; 4,807,096; 6,042,253; 5,669,698; 7,195,381; 6,971,775 and/or 7,249,860, microphones, such as disclosed in U.S. Pat. Nos. 7,657,052; 6,243,003; 6,278,377 and/or 6,420,975, speakers, antennas, including global positioning system (GPS) or cellular phone antennas, such as disclosed in U.S. Pat. No. 5,971,552, a communication module, such as disclosed in U.S. Pat. No. 5,798,688, a voice recorder, a blind spot detection system, such as disclosed in U.S. Pat. Nos. 7,720,580; 7,038,577; 6,882,287; 5,929,786 and/or 5,786,772, transmitters and/or receivers, such as for a garage door opener or a vehicle door unlocking system or the like (such as a remote keyless entry system), a digital network, such as described in U.S. Pat. No. 5,798,575, a high/low headlamp controller, such as a camera-based headlamp control, such as disclosed in U.S. Pat. Nos. 5,796,094 and/or 5,715,093, a memory mirror system, such as disclosed in U.S. Pat. No. 5,796,176, a hands-free phone attachment, an imaging system or components or circuitry or display thereof, such as an imaging and/or display system of the types described in U.S. Pat. Nos. 7,400,435; 7,526,103; 6,690,268 and/or 6,847,487, and/or U.S. Pat. Pub. No. US-2006-0125919, a video device for internal cabin surveillance (such as for sleep detection or driver drowsiness detection or the like) and/or video telephone function, such as disclosed in U.S. Pat. Nos. 5,760,962 and/or 5,877,897, a remote keyless entry receiver, a seat occupancy detector, a remote starter control, a yaw sensor, a clock, a carbon monoxide detector, status displays, such as displays that display a status of a door of the vehicle, a transmission selection (4wd/2wd or traction control (TCS) or the like), an antilock braking system, a road condition (that may warn the driver of icy road conditions) and/or the like, a trip computer, a tire pressure monitoring system (TPMS) receiver (such as described in U.S. Pat. Nos. 6,124,647; 6,294,989; 6,445,287; 6,472,979; 6,731,205 and/or 7,423,522, and/or an ONSTAR® system, a compass, such as disclosed in U.S. Pat. Nos. 5,924,212; 4,862,594; 4,937,945; 5,131,154; 5,255,442 and/or 5,632,092, and/or any other accessory or circuitry or the like (with all of the above-referenced patents and publications being commonly assigned and being hereby incorporated herein by reference in their entireties).

The mirror assembly may comprise or utilize aspects of other types of casings or the like, such as described in U.S. Pat. Nos. 7,338,177; 7,289,037; 7,249,860; 6,439,755; 4,826,289 and/or 6,501,387, which are all hereby incorporated herein by reference in their entireties, without affecting the scope of the present invention. For example, the mirror assembly may utilize aspects of the flush or frameless or bezelless reflective elements described in U.S. Pat. Nos. 7,626,749; 7,360,932; 7,289,037; 7,255,451; 7,274,501 and/or 7,184,190, which are all hereby incorporated herein by reference in their entireties.

Optionally, the mirror assembly may comprise a modular mirror construction, and may include back housing portions or the like, such as cap portions of the types described in U.S. Pat. No. 7,289,037, which is hereby incorporated herein by reference in its entirety. A display screen may be provided as a modular display screen and may be mountable or installable in the appropriate or suitable mirror casing to provide a modular mirror assembly and display screen. For example, a rear casing or cap portion may include the display screen module including the associated components, such as the rails and motor and the like for a video slideout module (such as by utilizing aspects of the video mirrors described in U.S. Pat. Nos. 7,370,983 and 6,690,268, and/or U.S. Pat. Pub. Nos. US-2006-0050018 and/or US-2009-0015736, which are hereby incorporated herein by reference in their entireties), and may be attachable to a reflective element and/or mirror casing to assemble the modular mirror assembly. The display screen module thus may be provided as an optional component or accessory for a vehicle, and may be readily assembled to a common reflective element and/or mirror casing of the mirror assembly.

Optionally, the mirror casing and/or reflective element may include customized or personalized viewable characteristics, such as color or symbols or indicia selected by the vehicle manufacturer or owner of the vehicle, such as the customization characteristics described in U.S. Pat. Nos. 7,626,749; 7,255,451 and/or 7,289,037, which are hereby incorporated herein by reference in their entireties.

Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. 

1. A method of manufacturing a rearview mirror assembly for a vehicle, said method comprising: providing an electro-optic reflective element having a front substrate and a rear substrate and an electro-optic medium sandwiched therebetween, wherein the front substrate has a first surface and a second surface with a transparent electrically conductive coating at the second surface and in contact with the electro-optic medium, and wherein the rear substrate has a third surface and a fourth surface with an electrically conductive coating at the third surface and in contact with the electro-optic medium; establishing a first electrically conductive element at the fourth surface of the rear substrate that is in electrical connection with the transparent electrically conductive coating at the second surface of the front substrate; establishing a second electrically conductive element at the fourth surface of the rear substrate that is in electrical connection with the electrically conductive coating at the third surface of the rear substrate; providing a back plate, wherein the back plate has first and second passageways established therethrough; disposing a first spring-loaded electrical connector in the first passageway of the back plate; disposing a second spring-loaded electrical connector in the second passageway of the back plate; providing a circuit element having electro-optic control circuitry established thereat, wherein the circuit element has first and second electrically conductive traces in electrical connection with the electro-optic control circuitry; attaching the back plate at the reflective element; attaching the circuit element at the back plate; and wherein, with the back plate attached at the reflective element and with the circuit element attached at the back plate, (i) the first spring-loaded electrical connector is biased into electrical contact with the first electrically conductive element and is biased into electrical contact with the first electrically conductive trace to electrically connect the first electrically conductive trace to the first electrically conductive element and (ii) the second spring-loaded electrical connector is biased into electrical contact with the second electrically conductive element and is biased into electrical contact with the second electrically conductive trace to electrically connect the second electrically conductive trace to the second electrically conductive element.
 2. The method of claim 1, wherein disposing the first and second spring-loaded electrical connectors in the first and second passageways comprises movably disposing the first and second spring-loaded electrical connectors in the first and second passageways so that the first and second spring-loaded electrical connectors are longitudinally movable within and partially along the first and second passageways, respectively.
 3. The method of claim 1, wherein disposing the first spring-loaded electrical connector in the first passageway comprises disposing the first spring-loaded electrical connector in the first passageway and retaining the first spring-loaded electrical connector in the first passageway via a flange of the back plate in the first passageway and a pair of spaced apart flanges of the first spring-loaded electrical connector.
 4. The method of claim 3, wherein a first flange of the first spring-loaded electrical connector allows for insertion of the first spring-loaded electrical connector in a first direction into the first passageway past the flange of the back plate and, when engaging the flange of the back plate, limits movement of the first spring-loaded electrical connector in a second direction opposite the first direction, and wherein disposing the first spring-loaded electrical connector in the first passageway comprises inserting the first spring-loaded electrical connector into the first passageway in the first direction until the first flange passes the flange of the back plate.
 5. The method of claim 3, wherein, with the first spring-loaded electrical connector disposed in the first passageway, the first spring-loaded electrical connector is longitudinally movable within the first passageway and the longitudinal movement of the first spring-loaded electrical connector is limited by one of the flanges of the first spring-loaded electrical connector engaging the flange of the back plate.
 6. The method of claim 1, wherein, with the first and second spring-loaded electrical connectors disposed in the first and second passageways, respectively, a length dimension of the first and second spring-loaded electrical connectors when extended is greater than a thickness dimension of the back plate at the respective first and second passageways.
 7. The method of claim 6, wherein, with the first and second spring-loaded electrical connectors disposed in the first and second passageways, respectively, the first and second spring-biased electrical connectors protrude from opposite sides of the back plate.
 8. The method of claim 7, wherein attaching the back plate at the reflective element and attaching the circuit element at the back plate includes compressing the first and second spring-loaded electrical connectors.
 9. The method of claim 6, wherein attaching the back plate at the reflective element is done before attaching the circuit element at the back plate, and wherein attaching the circuit element at the back plate attached at the reflective element includes compressing the first and second spring-loaded electrical connectors.
 10. The method of claim 1, wherein the circuit element comprises a printed circuit board.
 11. The method of claim 10, wherein attaching the circuit element at the back plate comprises snap-attaching the printed circuit board at the back plate, and wherein, when the printed circuit board is snap-attached at the back plate with the back plate attached at the reflective element, the first spring-loaded electrical connector is biased into engagement with the first electrically conductive element and the first electrically conductive trace to electrically connect the first electrically conductive trace to the first electrically conductive element.
 12. The method of claim 1, wherein the first spring-loaded electrical connector comprises a first electrically conductive body portion and a second electrically conductive body portion movable relative to the first electrically conductive body portion and in electrical conductivity therewith, and wherein the first electrically conductive body portion comprises a reflective element-contacting end that, when the first spring-loaded electrical connector is disposed in the first passageway, contacts the first electrically conductive element at the fourth surface of the rear substrate, and wherein the second electrically conductive body portion comprises a circuitry-contacting end that, when the first spring-loaded electrical connector is disposed in the first passageway, contacts the first electrically conductive trace at the circuit element.
 13. The method of claim 12, wherein the first spring-loaded electrical connector comprises a spring element disposed at least partially in the first and second electrically conductive body portions, and wherein the spring element urges the first electrically conductive body portion outward from the second electrically conductive body portion.
 14. The method of claim 13, wherein the spring element comprises an electrically conductive spring element.
 15. The method of claim 1, wherein the rearview mirror assembly comprises an interior rearview mirror assembly and is configured for mounting at an interior portion of a vehicle.
 16. The method of claim 1, wherein the rearview mirror assembly comprises an exterior rearview mirror assembly and is configured for mounting at an exterior portion of a vehicle.
 17. A method of manufacturing a rearview mirror assembly for a vehicle, said method comprising: providing an electro-optic reflective element having a front substrate and a rear substrate and an electro-optic medium sandwiched therebetween, wherein the front substrate has a first surface and a second surface with a transparent electrically conductive coating at the second surface and in contact with the electro-optic medium, and wherein the rear substrate has a third surface and a fourth surface with an electrically conductive coating at the third surface and in contact with the electro-optic medium; establishing a first electrically conductive element at the fourth surface of the rear substrate that is in electrical connection with the transparent electrically conductive coating at the second surface of the front substrate; establishing a second electrically conductive element at the fourth surface of the rear substrate that is in electrical connection with the electrically conductive coating at the third surface of the rear substrate; providing a back plate, wherein the back plate has first and second passageways established therethrough; disposing a first spring-loaded electrical connector in the first passageway of the back plate, wherein, with the first spring-loaded electrical connector disposed in the first passageway of the back plate, opposite ends of the first spring-loaded electrical connector protrude from respective sides of the back plate; disposing a second spring-loaded electrical connector in the second passageway of the back plate, wherein, with the second spring-loaded electrical connector disposed in the second passageway of the back plate, opposite ends of the second spring-loaded electrical connector protrude from respective sides of the back plate; providing a circuit element having electro-optic control circuitry established thereat, wherein the circuit element has first and second electrically conductive traces in electrical connection with the electro-optic control circuitry; attaching the back plate at the reflective element; attaching the circuit element at the back plate; and wherein, with the back plate attached at the reflective element and with the circuit element attached at the back plate, (i) the first spring-loaded electrical connector is compressed to a compressed state and is biased toward an extended state such that the opposite ends of the first spring-loaded electrical connector are urged into electrical contact with the first electrically conductive element and the first electrically conductive trace to electrically connect the first electrically conductive trace to the first electrically conductive element and (ii) the second spring-loaded electrical connector is compressed to a compressed state and is biased toward an extended state such that the opposite ends of the second spring-loaded electrical connector are urged into electrical contact with the second electrically conductive element and the second electrically conductive trace to electrically connect the second electrically conductive trace to the second electrically conductive element.
 18. The method of claim 17, wherein disposing the first and second spring-loaded electrical connectors in the first and second passageways comprises movably disposing the first and second spring-loaded electrical connectors in the first and second passageways so that the first and second spring-loaded electrical connectors are longitudinally movable within and partially along the first and second passageways, respectively.
 19. The method of claim 17, wherein, with the first spring-loaded electrical connector disposed in the first passageway, longitudinal movement of the first spring-loaded electrical connector is limited by at least one flange of the first spring-loaded electrical connector and at least one flange of the back plate at the first passageway, and wherein, with the second spring-loaded electrical connector disposed in the second passageway, longitudinal movement of the second spring-loaded electrical connector is limited by at least one flange of the second spring-loaded electrical connector and at least one flange of the back plate at the second passageway.
 20. A method of manufacturing a rearview mirror assembly for a vehicle, said method comprising: providing an electro-optic reflective element having a front substrate and a rear substrate and an electro-optic medium sandwiched therebetween, wherein the front substrate has a first surface and a second surface with a transparent electrically conductive coating at the second surface and in contact with the electro-optic medium, and wherein the rear substrate has a third surface and a fourth surface with an electrically conductive coating at the third surface and in contact with the electro-optic medium; establishing a first electrically conductive element at the fourth surface of the rear substrate that is in electrical connection with the transparent electrically conductive coating at the second surface of the front substrate; establishing a second electrically conductive element at the fourth surface of the rear substrate that is in electrical connection with the electrically conductive coating at the third surface of the rear substrate; providing a back plate, wherein the back plate has first and second passageways established therethrough; disposing a first spring-loaded electrical connector in the first passageway of the back plate; wherein the first spring-loaded electrical connector comprises (i) a first electrically conductive reflective element-contacting body portion and (ii) a first electrically conductive circuitry-contacting body portion movable relative to the first electrically conductive reflective element-contacting body portion and in electrical conductivity therewith; wherein the first spring-loaded electrical connector comprises a first spring disposed within a cavity formed by the first electrically conductive reflective element-contacting body portion and the first electrically conductive circuitry-contacting body portion, and wherein the first spring biases the first spring-loaded electrical connector toward an extended state; disposing a second spring-loaded electrical connector in the second passageway of the back plate; wherein the second spring-loaded electrical connector comprises (i) a second electrically conductive reflective element-contacting body portion and (ii) a second electrically conductive circuitry-contacting body portion movable relative to the second electrically conductive reflective element-contacting body portion and in electrical conductivity therewith; wherein the second spring-loaded electrical connector comprises a second spring disposed within a cavity formed by the second electrically conductive reflective element-contacting body portion and the second electrically conductive circuitry-contacting body portion, and wherein the second spring biases the second spring-loaded electrical connector toward an extended state; providing a circuit element having electro-optic control circuitry established thereat, wherein the circuit element has first and second electrically conductive traces in electrical connection with the electro-optic control circuitry; wherein the circuit element comprises a printed circuit board; attaching the back plate at the reflective element; attaching the circuit element at the back plate; wherein, when the first spring-loaded electrical connector is disposed in the first passageway and when the back plate is attached at the reflective element and the circuit element is attached at the back plate, the first electrically conductive reflective element-contacting body portion of the first spring-loaded electrical connector contacts the first electrically conductive element at the fourth surface of the rear substrate and the first electrically conductive circuitry-contacting body portion of the first spring-loaded electrical connector contacts the first electrically conductive trace at the circuit element; and wherein, when the second spring-loaded electrical connector is disposed in the second passageway and when the back plate is attached at the reflective element and the circuit element is attached at the back plate, the second electrically conductive reflective element-contacting body portion of the second spring-loaded electrical connector contacts the second electrically conductive element at the fourth surface of the rear substrate and the second electrically conductive circuitry-contacting body portion of the second spring-loaded electrical connector contacts the second electrically conductive trace at the circuit element.
 21. The method of claim 20, wherein, with the first and second spring-loaded electrical connectors disposed in the first and second passageways, respectively, a length dimension of the first and second spring-loaded electrical connectors when extended is greater than a thickness dimension of the back plate at the respective first and second passageways.
 22. The method of claim 21, wherein attaching the back plate at the reflective element and attaching the circuit element at the back plate includes compressing the first and second spring-loaded electrical connectors.
 23. The method of claim 20, wherein each of the first and second springs comprises an electrically conductive spring. 